Manual Guia Rpido - WEG-CESTARI - Rev02 - 09-2019 PDF

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Manual de Instalação, Operação e Manutenção

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Manual de Instalación, Operación y Mantenimiento
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Installation, Operation and Maintenance Manual
Redutores, Motorredutores, Partes e Peças

Reductores, Motorreductores de Velocidad, Partes y Piezas
Gear Units, Gearmotors and Spare Parts
www.wegcestari.com

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02 - 09/2019
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PORTUGUÊS
1. CONSIDERAÇÕES GERAIS
O objetivo deste manual é fornecer informações importantes que devem ser observadas durante o
transporte, armazenagem, instalação, operação e manutenção dos produtos WEG-CESTARI
(redutores, motorredutores, partes e peças) e, por esse motivo, recomendamos ler atentamente as
instruções aqui contidas. A não observação das instruções indicadas neste manual, no manual do
motor (se fornecido) e do manual completo disponível no site: www.wegcestari.com na seção
“downloads”, anula a garantia do produto e pode resultar em sérios danos pessoais e materiais.
Quando tratar-se de motorredutor fornecido com motor WEG, o Manual de Instalação, Operação e
Manutenção do Motor encontra-se anexo a este manual e também deve ser atentamente observado.
Os redutores são fornecidos com uma placa de identificação (Fig.1) e os motorredutores são
fornecidos com duas placas de identificação, uma do redutor (Fig.1) e outra do motor (conforme padrão
do fabricante). As placas de identificação contêm símbolos e valores que determinam as
características do redutor e do motor. São fixadas em local facilmente visível; confeccionadas em
material resistente às intempéries.
Os dados contidos na Placa de Identificação do redutor são:
Código: Código do redutor ou motorredutor.

Série: Número de Série.
P1: Potência do Motor ou do Redutor (kW).
rpm: Rotação de saída do redutor.
M2: Torque de Saída (Nm).
fs: Fator de serviço.
i: Redução Total.
Peso: Peso do redutor sem o motor (kg).
Óleo: Tipo e Viscosidade do óleo a 40ºC.
P: Posição de Trabalho e Ano de fabricação. Figura 1
TAG: Espaço para Informações
Os motorredutores e redutores são fornecidos pintados com esmalte sintético padrão WEG-CESTARI
ou conforme solicitação específica do cliente.
2
2. TRANSPORTE, MANUSEIO E ARMAZENAGEM
Recomendamos que, quando do recebimento do nosso produto (redutor/motorredutor e/ou partes e

peças), seja verificado seu estado e se o mesmo corresponde ao especificado. Caso algum dano
tenha sido constatado no produto, solicitamos a imediata comunicação formal do fato a transportadora
e a WEG-CESTARI e nesse caso, nenhum trabalho de instalação deve ser iniciado antes que o
problema encontrado seja solucionado.
Quando da movimentação de redutores/motorredutores, utilize corda, cabos, cintas e equipamentos

de suspensão adequados para não pôr em risco vidas humanas e o próprio equipamento.
Os redutores/motorredutores deverão ser movimentados utilizando-se do parafuso de suspensão

(Fig.2A) e na inexistência deste, a unidade deverá ser suspensa através da carcaça do redutor
(Fig.2B), em conjunto com o olhal do motor (Fig.2C) respeitando o ângulo máximo de 60º entre os
cabos. Nunca suspenda o equipamento somente através do motor.
Figura 2A Figura 2B Figura 2C
Antes de levantar totalmente o redutor/motorredutor, certifique-se de estar a carga devidamente

balanceada. Todo manuseio do redutor/motorredutor deve ser realizado de maneira suave para evitar
impactos e danos no redutor/motorredutor, principalmente nas pontas dos eixos.
Os produtos WEG-CESTARI (redutores, motorredutores, partes e peças) devem ser armazenados em

sua embalagem original em ambiente fechado (não expostos diretamente aos raios solares ou raios
UV), seco, protegido contra insetos, livre de poeira, umidade do ar inferior a 60%, isentos de gases,
fungos, agentes corrosivos (ar contaminado, ozônio, gases, solventes, ácidos, alcalina, sais,
radioatividade, etc.) e temperatura ambiente entre -5ºC a +40ºC.
3
Os redutores/motorredutores da WEG-CESTARI deverão ser armazenados na posição de trabalho
especificada e fornecida, em superfície plana sobre estrados ou em prateleiras apropriadas (não em
contato direto com o piso) e não disposto em local com trepidação e oscilações.
2.1 Período sem funcionamento
Os redutores/motorredutores WEG-CESTARI saem de fábrica e devem ser postos em operação

dentro do período máximo de 6 meses.
Para períodos de 6 meses até 9 meses sem operação, é recomendado preencher todo interior do
redutor com lubrificantes apropriados (lubrificante recomendado ver manual do produto disponível no
site: www.wegcestari.com na seção “downloads” ). Preencher o redutor com óleo até a parte
superior (logo abaixo do respiro), garantindo assim, que todas suas engrenagens e rolamentos fiquem
imersos em óleo. O eixo de entrada do redutor deverá ser girado no mínimo duas voltas completas e
este procedimento deverá ser repetido, no mínimo, 1 vez a cada 2 meses.
NOTAS: Antes da operação, o lubrificante do redutor/motorredutor deverá ser drenado até o nível
adequado para operação (centro do visor de nível ou no nível quando do tipo bujão
sextavado modelo HN10-WD – similar DIN 510)
Para os redutores das linhas: Alumag, Magma M e WCG20, o volume adequado de
lubrificante deve ser consultado no manual do produto disponível no site:
www.wegcestari.com na seção “downloads”
Proteger os retentores externamente com graxa e nos redutores que possuem vedação labirinto
(“taconite”), para um período sem funcionamento acima de 6 meses, aplicar uma fina camada de graxa
na superfície externa para prevenir ressecamento. A graxa deve ser removida antes do início da
operação (graxa recomendada NLGI#2EP Texaco Multifak EP2 ou similar).
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No start-up do equipamento é bem possível e provável que ocorra
uma pressão mais elevada acusando “entupimento” do elemento
filtrante. Após poucas horas de funcionamento, a pressão do sistema
deverá cair para a faixa de trabalho de 0,8bar a 8bar.
Quando o sistema de lubrificação for elétrico, o motor da bomba deve

ser acionado antes do motor principal para evitar falta de lubrificação
nos componentes. Para a lubrificação mecânica, a rotação de
entrada do redutor deve ser a especificada em projeto (ver
dimensional e dados de entrada do redutor) com variação máxima de
+/- 7% para evitar a deficiência na vazão dimensionada para o
redutor.
O sistema de refrigeração pode ser por serpentina imersa no óleo lubrificante; trocador de calor casco-
tubo água-óleo ou radiador ar-óleo. A temperatura da água na entrada do trocador de calor ou
serpentina deve ser máximo 30°C.
Para redutor com sistema de lubrificação forçada, após abastecer o redutor de óleo até a metade do
visor, acionar o sistema para encher todo o circuito, e completar novamente com óleo até a metade
do visor.
Consultar a WEG-CESTARI para obtenção da vazão e qualidade de água recomendada; manutenção,

instalação e maiores informações dos sistemas de refrigeração e lubrificação.
15
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16
6. MANUTENÇÃO
A manutenção preventiva periódica visa principalmente verificar as condições de funcionamento do

motorredutor/redutor. Ela deve ser executada por pessoas qualificadas.
Não existem regras rígidas a serem seguidas quando se aborda programas de inspeção. Os
períodos ou intervalos, os tipos de exames a serem realizados podem ser prolongados ou reduzidos
de acordo com as condições de trabalho e local onde está instalado o redutor.
Recomenda-se que cada motorredutor/redutor possua algum tipo de anotação própria, como ficha,
cartões ou etiqueta. O importante é registrar todas as manutenções executadas, as peças trocadas e
as datas em que foram realizadas. A análise destas anotações permitiria remanejos e acertos no
programa de manutenção.
Na tabela abaixo é apresentado um programa básico para inspeção, contendo os itens a serem
inspecionados e os intervalos de tempos sugeridos; porém, tais intervalos são flexíveis, prolongados
ou reduzidos, de acordo com as condições do local onde está instalado o motorredutor/redutor:
Roteiro de Manutenção
Itens a verificar Procedimentos Periodicidade
Condições Examinar a presença de ruídos ou vibrações anormais,vaza-

mecânicas
mento de óleo, inspecionar também as condições do sistema Semanal
de transmissão verificando lubrificação e alinhamento
Local onde está Identificar a existência de água ou vapores junto ao motorre-

instalado o dutor, excesso de poeira, aparas ou resíduos, verificar o
respiro do redutor, desentupindo-o se for o caso, verificar as Semanal
motorredutor
condições de ventilação do motor elétrico.
Nível de óleo Verifique o nível de óleo e, se necessário complete-o. Semanal

Parafusos de fixação Verificar se por vibração não houve afrouxamento
do motorredutor dos parafusos de fixação do motorredutor. Mensal
Terminais Observar se, por vibração não houve o afrouxamento dos

e parafusos e pontes de ligação, tornando deficiente o contato Mensal
parafusos e prejudicando o fornecimento de energia.
Examinar as condições, dos elementos de transmissão,

Condições substituindo-os se necessário, limpando a carcaça e tampas
mecânicas do motorredutor. Semestral
Verificar se há falta de alinhamento ou algo atritando.
17
18
DEFEITOS EM REDUTORES
SINTOMAS CAUSAS MEDIDAS CORRETIVAS

Verifique a capacidade indicada na plaqueta do redutor, substitua por uma
Sobrecarga Carga excede a capacidade do redutor.
unidade de capacidade suficiente, ou reduza a carga.
Volume de óleo insuficiente.
Lubrificação Óleo em demasia no redutor provoca excessiva agitação, Verifique o nível de óleo, ajuste o nível para a posição correta.
imprópria geração de calor e gases no interior da caixa.
excessivo
Aquecimento
Drene e encha novamente para o nível de óleo adequado, com o óleo indicado
Óleo fora de especificação. na plaqueta do redutor ou similar.
Quantidade excessiva de óleo. Cheque o nível e drene para o nível indicado.
Retentores
Respirador para entrada de ar e saída de gases obstruído. Limpe ou substitua o respirador, use um solvente não inflamável para limpeza.
gastos
de
óleo
Substitua os retentores gastos por novos. Aplique nova camada de vedação,
Perda
ou Camadas de vedação entre as superfícies das caixas
permatex ou equivalente, monte o conjunto. Monte sempre os retentores com
defeituosos insuficientes. graxa nos lábios de vedação.
Irreguraridades Verifique o aperto dos parafusos e se os chumbadores estão firmes em suas
nos parafusos Instalação invertida fundações ou estruturas. Cheque o alinhamento da unidade e as folhas
de fixação distanciadoras ou calços.
Fadiga dos rolamentos, verifique desgaste nas esferas, Substitua os rolamentos gastos, limpe todo o interior do redutor e recoloque óleo
rolos ou pistas. Desgaste pode ser por sujeira no óleo. novo, conforme o especificado.
Falha Pistas dos rolamentos com descascamentos, marcadas ou
nos com flancos machucados geralmente indicam sobrecarga. Substitua os rolamentos gastos, cheque e repare folgas nos rolamentos,
rolamentos Falha nas gaiolas dos rolamentos também indicam alinhamento dos acoplamentos e cargas sobre os eixos dos redutores.
sobrecarga.
Excessivo desgaste Sobrecarga causa Pitting dos dentes (escovação, Cheque as cargas, troque as engrenagens ou substitua por redutor de
das engrenagens pequenos furos). capacidade adequada.
Quantidade de
óleo insuficiente Óleo abaixo do nivel normal pode causar barulho. Cheque o nível de óleo complete para o nível indicado
Choques excessivos ou conexão imperfeita com outros Inspecione o redutor contra partes quebradas, perda de parafusos, porcas ou
Perdas de partes roscas danificadas. Verifique o alinhamento com a máquina acionada. Cheque
Barulho excessivo e vibração

elementos.
as chavetas e tolerâncias.
Alta velocidade Tensão excessiva nas correias ou correntes de Cheque velocidades indicadas na plaqueta. Verifique as tensões.
dos eixos acionamentos.
Folga
Rolamento expostos a elementos abrasivos causam desgaste nas esferas, rolos Substitua rolamentos gastos. Limpe todo o interior da caixa, alimente a unidade
excessivas de
e pistas. com óleo recomendado.
eixos
Folga Engrenagens e chavetas gastas ou perda dos parafusos causam blacklash

excessivas nas (folga no engrenamento); blacklash aumenta com o número de jogos de Substitua engrenagens e chavetas gastas. Aperte todos os parafusos da unidade.
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22
9. ORIENTAÇÕES AMBIENTAIS
Os produtos fabricados pela WEG-CESTARI atendem aos requisitos legais e ambientais definidos
pela empresa e como parte integrante do nosso Sistema de Gestão Ambiental, as informações
referentes à reciclagem dos nossos produtos são disponibilizadas neste Manual:
Carcaças, Acoplamentos, Tampas, etc. (Ferro Fundido, Aço ou Alumínio):

São 100% recicláveis e devem ser destinadas para fundições
Eixos, Engrenagens, Pinhões, etc. (Aço):

São 100% recicláveis e devem ser destinadas para siderúrgicas
Coroas (Bronze):
São 100% recicláveis e devem ser destinadas para fundições
Óleos:
Devem ser destinados para rerrefino em empresas devidamente autorizadas
Vedações (Borracha):
Devem ser destinadas a empresas devidamente licenciadas pelo órgão ambienta responsável
(aterro classe II)
Elementos Elásticos:
São 100% recicláveis e devem ser destinadas para empresas recicladoras
Embalagens:
Madeira: São fabricadas com madeira de reflorestamento e podem ser reutilizadas ou

destinadas como combustível em caldeiras quando não contaminadas (com óleo,
graxa, tinta).
Papelão: São 100% recicláveis quando não contaminadas (com óleo, graxa, tinta) e devem
ser destinadas para empresas recicladoras.
NOTA: Se algum material estiver contaminado com óleo, graxa, tinta, o mesmo deve ser
destinado a empresas devidamente licenciadas pelo órgão ambiental
responsável.
23
Check List - Instalação e Montagem de Redutores
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Recebimento
Verificação da Pintura
Verificar existência de riscos, descascamento e outras imperfeições
Verificação de Oxidação
Verificar presença de pontos ou áreas oxidadas no redutor e/ou
acessórios
Verificação de Vazamentos
Verificar presença de óleo em retentores, tampas e junções
Verificação de Proteção de Partes Usinadas
Verificar se partes usinadas estão protegidas com óleo protetor
Verificação de Componentes
Verificar se componentes utilizados na montagem estão presentes
Verificação de Lacres
Verificar se a válvula respiro está lacrada e se os componentes do
Sistema EasyLock estão lacrados
Verificação de condições de armazenagem
Verificar se o redutor foi acondicionado conforme instrução do manual
do produto
Instalação
Verificação da Posição de Trabalho
Verificar se o redutor está montado na posição para a qual foi fornecido
Verificação de Nível de Óleo Lubrificante
Realizar a verificação de nível de óleo lubrificante conforme manual
do produto
Verificação de Retirada do Lacre da Válvula Respiro
Verificar se o lacre da válvula respiro foi completamente removido
antes de colocar o redutor em operação
Verificação dos Elementos de Vedação
Verificar retentores, tampas e demais elementos de vedação para
vazamentos e/ou defeitos/deformidades desses elementos
Verificação da Instalação do Redutor
Verificar se a colocação do redutor na máquina acionada seguiu as
recomendações do manual do produto
24
Verificação do Sistema Easy-Lock
Verificar se o Sistema Easy-Lock foi instalado conforme instruções do
manual do produto
Aplicação de Óleo Pretetivo em Partes Usinadas
Verificar se foi aplicado óleo protetivo nas partes usinadas APÓS
instalação do redutor na máquina
Remoção do Lacre da Válvula Respiro
Posição de Trabalho
O respiro deve estar
sempre no lado superior
Verificado em:
_______/_______/_________
Responsável pela Verificação:
Assinatura:
25
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27
ESPAÑOL
1. CONSIDERACIONES GENERALES
El objetivo de este manual es suministrar informaciones importantes que deben ser observadas
durante el transporte, almacenamiento, instalación, operación y mantenimiento de los productos WEG-
CESTARI (reductores, motorreductores, partes y piezas) y, por ese motivo, recomendamos leer
atentamente las instrucciones aquí contenidas. El no seguimiento de las instrucciones indicadas en
este manual, en el manual del motor (siendo suministrado) y del manual completo disponible en el sitio
web: www.wegcestari.com en la sección “downloads”, anula la garantía del producto, resultando
en serios daños personales y materiales.
Cuando se trate de motorreductor suministrado con motor WEG, el Manual de Instalación, Operación
y Mantenimiento del Motor se encuentra adjunto a este manual, debiendo, también, ser seguido
atentamente.
Los reductores son suministrados con una placa de identificación (Fig.1) mientras que los
motorreductores son suministrados con dos placas de identificación, una del reductor (Fig.1) y otra del
motor (estándar del fabricante). Las placas de identificación contienen símbolos y valores que
determinan las características del reductor y del motor. Son fijadas en local fácilmente visible; hechas
de material resistente a intemperies.
Los datos contenidos en la Placa de Identificación del reductor son:
Código: Código del reductor o motorreductor.

Serie: Numero de serie.
P1: Potencia del Motor o Reductor (kW).
rpm: Rotación de salida del reductor (rpm).
M2: Par de salida (Nm).
fs: Factor de servicio.
i: Reducción total.
Peso: Peso del reductor sin motor (kg).
Aceite: Tipo y Viscosidad del aceite a 40ºC.
P: Posición de Trabajo y Año de fabricación
Figura 1
TAG: Espacio para Información.
Los motorreductores y reductores son suministrados pintados con esmalte sintético estándar WEG-
CESTARI, o de acuerdo a la solicitud específica del cliente.
28
2. TRANSPORTE, MANIPULACIÓN Y ALMACENAMIENTO
Recomendamos que, al recibir nuestro producto (reductor/motorreductor y/o partes y piezas), sea
verificado su estado y si el producto corresponde al especificado. En caso de que haya sido constatado
algún daño en el producto, solicitamos la inmediata comunicación formal del hecho a la transportadora
y a WEG-CESTARI, en ese caso, no deberá ser iniciado ningún trabajo de instalación, antes de que
el problema encontrado sea solucionado.
Tratándose del movimiento de los reductores/motorreductores, utilice cuerda, cables, cintas y equipos
de suspensión adecuados para no poner en riesgo vidas humanas o al propio equipo.
Los reductores/motorreductores deberán ser movidos haciendo uso del cáncamo de izaje (Fig.2A),
ante la inexistencia de éste, la unidad deberá ser suspendida a través de la carcasa del reductor
(Fig.2B), en conjunto con el cáncamo del motor (Fig.2C) respetando el ángulo máximo de 60º entre
los cables. Jamás izar el equipo solamente a través del motor.
Figura 2A Figura 2B Figura 2C
Antes de levantar totalmente el reductor/motorreductor, asegúrese de que la carga esté debidamente

balanceada. Toda manipulación del reductor/motorreductor debe ser realizada de manera suave, para
así evitar choques y daños en el reductor/motorreductor, principalmente en las puntas de los ejes.
Los productos WEG-CESTARI (reductores, motorreductores, partes y piezas) deben ser almacenados
en su embalaje original en ambiente cerrado (no expuestos directamente a los rayos solares o rayos
UV), seco, protegido contra insectos, libre de polvo, humedad del aire inferior a 60%, exentos de
gases, hongos, agentes corrosivos (aire contaminado, ozono, gases, solventes, ácidos, alcalina,
sales, radioactividad, etc.) y a una temperatura ambiente entre -5ºC y +40ºC.
29
Los reductores/motorreductores de WEG-CESTARI deberán ser almacenados en la posición de
trabajo especificada y suministrada, en superficie plana, sobre tarimas o en estanterías apropiadas
(no en contacto directo con el piso) ni dispuesto en local con trepidación u oscilaciones.
2.1 Período sin funcionamiento
Los reductores/motorreductores WEG-CESTARI, al salir de fábrica, deberán ser puestos en operación

dentro del período máximo de 6 meses.
Para períodos desde 6 a 9 meses sin operación, es recomendado llenar todo interior del reductor con
lubricantes apropiados (lubricante recomendado ver manual del producto disponible en el sitio:
www.wegcestari.com en la sección “downloads” ). Llenar el reductor con aceite hasta la parte
superior (por debajo del respiradero), garantizando así, que todos sus engranajes y rodamientos se
queden sumergidos en aceite. El eje de entrada del reductor deberá ser girado un mínimo de dos
vueltas completas y este procedimiento deberá ser repetido, como mínimo, 1 vez cada 2 meses.
NOTAS: Antes de la puesta en marcha, el lubricante del reductor/motorreductor deberá ser

drenado hasta el nivel adecuado para operación (centro del visor de nivel o en el nivel,
cuando sea el tipo tapón sextavado modelo HN10-WD – similar DIN 510)
Para los reductores de las líneas: Alumag, Magma M y WCG20, el volumen adecuado
de lubricante debe ser consultado en el manual del producto, disponible en el sitio web:
www.wegcestari.com en la sección “downloads”
Proteger los retenes externamente con grasa y en los reductores que poseen sellado laberinto
(“Taconite”). Para un período sin funcionamiento mayor a 6 meses, aplicar una película de grasa en la
superficie externa, para prevenir resecamiento. La grasa deberá ser removida antes del inicio de la
operación (grasa recomendada NLGI#2EP Texaco Multifak EP2 o similar).
30
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En el start-up del equipo es posible y probable que ocurra una presión
más elevada, indicando “atasco” del elemento filtrante. Luego de
pocas horas de funcionamiento, la presión del sistema deberá caer
al rango de trabajo de 0,8bar a 8bar.
Cuando el sistema de lubricación es eléctrico, el motor de la bomba

debe ser accionado antes del motor principal para evitar la falta de
lubricación en los componentes. Para la lubricación mecánica, la
rotación de entrada del reductor debe ser la especificada en diseño
(ver dimensional y datos de entrada del reductor) con variación
máxima de +/- 7% para evitar la deficiencia en el caudal
dimensionado para el reductor.
El sistema de refrigeración puede ser por serpentin sumergido en aceite lubricante; intercambiador de
calor casco-tubo agua-aceite o radiador aire-aceite. La temperatura del agua en la entrada del
intercambiador de calor o del serpentin debe ser de un máximo de 30°C.
Para reductor con sistema de lubricación forzada, tras llenarlo con aceite hasta la mitad del visor,
accionar el sistema para llenar todo el circuito y completar nuevamente con óleo hasta la mitad del
visor.
Consultar a WEG-CESTARI para obtener el caudal y la calidad del agua recomendada;

mantenimiento, instalación y mayores informaciones de los sistemas de refrigeración y lubricación.
41
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6. MANTENIMIENTO
El mantenimiento preventivo periódico tiene, principalmente, como objetivo verificar las condiciones
de funcionamiento del motorreductor/reductor. Éste debe ser ejecutado por personas cualificadas.
No existen reglas rígidas a seren seguidas cuando se abordan programas de inspección. Los
períodos o intervalos, así como los tipos de examenes a seren realizados, pueden ser alargados o
reducidos de acuerdo con las condiciones de trabajo y el local donde está instalado el reductor.
Se recomienda que cada motorreductor/reductor posea algún tipo de anotación propia, como ficha,
tarjetas o etiqueta. Lo importante es registrar todos los mantenimientos ejecutados, las piezas
cambiadas y las fechas en que fueron realizados. El análisis de estas anotaciones permitirá cambios
y mejorías en el programa de mantenimiento.
En la tabla de abajo esta presentado un programa básico para inspección, conteniendo los ítems a
ser inspeccionados y los intervalos de tiempo sugeridos; no obstante, tales intervalos son flexibles,
alargados o reducidos, de acuerdo con las condiciones del local donde está instalado el
motorreductor/reductor:
Itinerário de Mantenimiento
Ítems a verificar Procedimientos Periodicidad

Examinar la presencia de ruidos o vibraciones anormales, pérdida
Condiciones Semanal
de aceite, inspeccionar también las condiciones del sistema de
mecánicas transmisión, verificando la lubricación y la alineación
Identificar la presencia de agua o vapores junto al motorreductor,

Local donde está
exceso de polvo o residuos. Verificar la respiración del reductor,
instalado el Semanal
desobstruyéndolo si fuera necesario, verificar las condiciones de
motorreductor ventilación del motor eléctrico.
Nivel de Aceite Verifique el nivel de aceite y, si fuera necesario, complételo Semanal
Tornillos de Verificar si hubo aflojamiento de los tornillos de fijación del

fijación del motorreductor, debido a vibración. Mensual
motorreductor
Terminales Verificar que, debido a vibración, no se hayan aflojado los tornillos

y ni los puentes de conexión, lo que tornaria deficiente el contacto Mensual
Tornillos y perjudicaria el suministro de energia
Examinar las condiciones de los elementos de transmisión,

Candiciones sustituyéndolos en caso necesario, limpiando la carcasa y Semestral
mecánicas las tapasdel motorreductor. Verificar que haya no falta de
alineación y que no haya nada produciendo roce
44
Fallas en los Reductores
SÍNTOMA CAUSAS MEDIDAS CORRECTIVAS
Sobrecarga La carga excede la capacidad del reductor Verifique la capacidad indicada en la placa del reductor, sustitúyalo por una
unidad de capacidad suficiente, o reduzca la carga.
Volumen de aceite insuficiente.
Aceite en demasía en el reductor provoca agitación Verifique el nivel de aceite, ajústelo en la posición correcta.
Lubrificación
excesiva, generación de calor y gases en el interior de la caja
excesivo
impropia
Drene y llene nuevamente con el nivel de aceite adecuado, con el aceite indicado
Calentamiento
Volumen de aceite insuficiente.
en la placa del reductor o similar.
Cantidad excesiva de aceite Verifique el nivel y drene hasta el nivel indicado.
Retenes Respirador, para entrada de aire y salida de gases, obstruido. Limpie o sustituya el respirador, use un solvente no inflamable para limpieza.
gastados o
de
Insuficientes camadas de sellado entre las superficies Sustituya los retenes gastados por nuevos. Aplique una nueva camada de sellado,
defectuosos
aceite
permatex o equivalente, monte el conjunto. Monte siempre los retenes con grasa
Perdida
de las cajas
en los labios de sellado.
Irregularidades Verifique el apriete de los tornillos y si los ancladores están firmes en sus cimientos
en los tornillos Instalación invertida o estructuras. Verifique la alineación de la unidad y las hojas distanciadoras
de fijación o calces.
Fatiga de los rodamientos, verifique el desgaste en las esferas, rodillos Sustituya los rodamientos gastados, limpie todo el interior del reductor y recoloque
o pistas. La causa del desgaste puede ser suciedad en el aceite aceite nuevo, conforme lo especificado
Falla en los Pistas de los rodamientos descascaradas, marcadas o con flancos
rodamientos magullados generalmente indican sobrecarga Sustituya los rodamientos gastados, verifique y repare holguras, alineación de
los acoplamientos y cargas sobre los ejes de los reductores.
Falla en las jaulas de los rodamientos también indican sobrecarga
Excesivo desgaste La sobrecarga causa Pitting de los dientes (cepillado, Verifique las cargas, cambie los engranejes o sustituya por reductor de
de los engranajes pequeños agujeros) capacidad adecuada
Cantidad de aceite
insuficiente Aceite por debajo del nivel normal puede causar barullo. Verifique el nivel de aceite, ajústelo al nivel indicado.
Pérdidas Choques excesivos o conexión imperfecta con Inspeccione el reductor contra partes quebradas, pérdida de tornillos, tuercas o
otros elementos.
roscas dañadas. Verifique la alineación con la máquina accionada.
de partes
Barulho excesivo y vibración

Verifique las chavetas y las tolerancias.
Alta velocidad Tensión excesiva en las correas o cadenas de accionamientos Verifique las velocidades indicadas en la placa. Verifique las tensiones.
de los ejes
Holguras
Rodamientos expuestos a elementos abrasivos causan desgaste en las esferas, Sustituya los rodamientos gastados. Limpie todo el interior de la caja.
excesivas rodillos y pistas alimente la unidad con el aceite recomendado
de ejes
Holguras Engranajes y chavetas gastadas o pérdida de los tornillos causan blacklash
Sustituya los engranajes y chavetas gastados.
excesivas en (holgura en el engranamiento); el blacklash aumenta con el número de juegos
Apriete todos los tornillos de la unidad
los engranajes de engranaje.
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Check List - Inslatación y Montaje de Reductores
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Recibimiento
Verificación de la Pintura
Verificar la existencia de rayones, defectos de pintura y otras imperfecciones
Verificación de Oxidación
Verificar si hay puntos o areas oxidadas en el reductor y/o accesorios
Verificación de Perdida de Aceite
Verificar si hay la perdida de aceite en los retenes y tapas
Verificación de Protección de las Partes Usinadas
Verificar si las partes usinadas están protegidas con aceite protector
Verificación de Componentes
Verificar si los componentes utilizados en el montaje están presentes
Verificación de Lacres
Verificar si el respiradero está lacrado y si los componentes del
sistema EasyLock están lacrados
Verificación de las Condiciones de Almacenaje
Verificar si el equipo fue almacenado conforme instrucciones del
manual del producto
Instalación
Verificación de la Posición de Trabajo
Verificar si el reductor está montado en la posición cuya cual fue
suministrado
Verificación del Nível de Aceite Lubricante
Realizar la verificación del nível de aceite lubricante conforme manual
del producto
Verificación de Retirada del Lacre del Respiradero
Verificar si el lacre del respiradero fue completamente retirado antes
de colocar el reductor en operación
Verificación de los Elementos de Sellado
Verificar retenes, tapas y otros elementos de sellado para chequear
posibles perdidas de aceite/defectos/deformidades
Verificación de la Instalación del Equipo
Verificar si el equipo fue colocado en la maquina siguiendo las
recomendaciones del manual del producto
50
Verificación del Sistema Easy-Lock
Verificar si el Sistema Easy-Lock fue instalado según instrucciones del
manuel del producto
Aplicación de Aceite Protetor en Partes Usinadas
Verificar si fue aplicado aceite protector en las partes usinadas después
de la instalación del reductor en las maquinas
Como quitar el lacre del respiradero
Posiciones de Trabajo
El respiradero siempre
debe estar em el lado
superior
Verificado en:
_______/_______/_________
Responsable por la Verificación:
Firma:
51
NOTAS
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ENGLISH
1. GENERAL CONSIDERATIONS
This manual provides important information which must be observed during shipment, storage,
installation, operation and maintenance of WEG-CESTARI products (gear units, gearmotors, parts and
pieces), and, therefore, we recommend carefully reading the instructions contained in this document.
Failure to comply with the instructions contained in this manual, in the motor manual (if provided) and
the complete manual available on: www.wegcestari.com in the "download" voids the product
warranty and may cause serious personal injuries and material damages.
When the gearmotor is supplied with a WEG motor, the Installation, Operation and Maintenance
Manual of the Motor is attached to this manual and should also be carefully observed.
The gear units are supplied with a nameplate (Fig.1) and the gearmotors are supplied with two
nameplates, one for the gear unit (Fig.1) and the other for the motor (according to the manufacturer's
standard). The nameplates contain symbols and values which determine the gear unit and motor
characteristics. They are affixed to a visible place and made of a bad-weather resistant material.
The data contained on the gear unit Nameplate are:
Type: Gear unit or gearmotor code.

Serial Number: Serial number.
P1: Motor or Gear unit power (kW).
rpm: Gear unit output speed (rpm).
M2: Output Torque (Nm).
sf: Gearmotor service factor.
i: Speed ratio.
Weight: Weight of the gear unit without motor (kg).
Oil: Type and viscosity of the oil at 40º C.
P: Mounting Position and Year of manufacturing. Figure 1
TAG: Space for Information.
The gearmotors and gear units are painted with WEG-CESTARI standard synthetic enamel or
according to the customer's specification.
54
2. TRANSPORTATION, HANDLING AND STORAGE
We recommend at the receipt of our product (gear unit/gearmotor and/or parts and pieces) to check its
conditions and if the product is compliant with the specifications. In case some damage is observed,
immediately notify the carrier and WEG-CESTARI, and do not start any installation works before the
problem is found and solved.
For moving and handling gear units/gearmotors, use proper ropes, lifting slings and lifting equipment
so as not to put people and the equipment itself at risk.
The gear units/gearmotors must be moved using the lifting eyebolt (Fig. 2A) and, if eyebolt is not
present, the unit must be lifted through the gear unit housing (Fig.2B), together with the eyebolt of the
motor (Fig.2C) observing the maximum angle of 60º between the cables. Never lift the equipment only
through the motor.
Figure 2A Figure 2B Figure 2C
Before completely lifting the gear unit/gearmotor, make sure the load is properly balanced. The gear
units/gearmotors must always be handled smoothly in order to avoid impacts and damages to the gear
unit/gearmotor, especially on the shaft ends.
WEG-CESTARI products (gear units/gearmotors, parts and pieces) must be stored in its original
package in a closed (not directly exposed to sunrays or UV rays) and dry environment protected against
vermin with relative humidity below 60% and free of dust, gases, fungi and corrosive agents
(contaminated air, ozone, gases, solvents, acids, alkaline products, salts, radioactivity, etc.). and
ambient temperature between -5ºC to +40ºC.
55
WEG-CESTARI gear units/gearmotors must be stored in the specified and supplied working position,
on a flat surface on proper platforms or shelves (not in direct contact with the floor) free of vibration
and oscillations.
2.1 Period out of operation
After leaving the factory, WEG-CESTARI gear units/gearmotors must be put into operation within the
maximum period of six months.
For periods from six months to nine months out of operation, it is recommended to fill the gear unit with
proper lubricants (for the recommended lubricant, see the product manual available on:
www.wegcestari.com in the “downloads” section). Fill the gear unit with oil to the upper part (right
below the breather), thus ensuring all the gears and rolling bearings are immersed in oil. The high-
speed shaft (the gear unit input shaft) must be turned at least two complete revolutions and this
procedure shall be repeated at least once every two months.
NOTES: Before operation, the gear unit/gearmotor lubricant must be drained down to the proper
operation level (center of the sight glass or at the level when hexagonal plug model HN10-
WD is used - DIN 510 similar).
For gear units of the lines: Alumag, Magma M and WCG20, the appropriate volume of
lubricant must be checked in the product manual available on www.wegcestari.com in
the "downloads" section.
Protect the lip seals externally with grease; on gear units that have taconite seals and will be out of
operation for more than six months, apply a thin layer of grease on the outer surface to prevent it from
drying out. The grease must be removed before starting operation (recommended grease NLGI#2EP
Texaco Multifak EP2 or similar product).
56
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It is quite possible and probable that, at the equipment start-up, a
higher pressure will occur, indicating "clogging" of the filter element.
After a few hours of operation, the system pressure should drop to the
working range of 0.8bar to 8bar.
When the lubrication system is electric, the pump motor must be

activated before the main motor to avoid lack of lubrication in the
components. For mechanical lubrication, the inlet speed of the gear
unit must be that specified in design (see dimensional and input data
of the gear unit) with a maximum variation of +/- 7% to avoid the
deficiency in the rated flow for the gear unit.
The cooling system can be through a coil immersed in lubricating oil; shell and tube water-oil heat
exchanger or air-oil cooler. The water temperature at the heat exchanger or coil inlet must be at most
30°C.
For gear units with a forced lubrication system, after filling the gear unit with oil up to the center of the
sight glass, put the system into operation to fill the entire circuit, and fill with oil up to the center of the
sight glass again.
Refer to WEG-CESTARI to obtain the recommended flow and quality of water, maintenance,
installation and more information on cooling and lubrication systems.
67
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68
6. MAINTENANCE
The regular preventive maintenance specially aims to check the operating conditions of the
gearmotor/gear unit. It must be performed by qualified personnel.
There are no rigid rules to be followed regarding inspection programs. The periods or intervals and
the types of examinations to be performed may be extended or reduced according to the working
conditions and the place where the gear unit is installed.
It is recommended that each gearmotor/gear unit have its own record, such as a card or label. It is
important to record all the maintenances, the parts changed and the dates when they were
performed. The analysis of those records will allow adjustments in the maintenance program.
The table below contains a basic inspection program with the items to be inspected and the
suggested intervals; however, such intervals are flexible, and they may be extended or reduced
according to the environment conditions where the gearmotor/gear unit is installed.
Maintenance Guide
Item to verify Procedures Frequency

Check for abnormal noise or vibrations, oil leaks, as well as the
Mechanical conditions conditions of the transmission system by examining the lubrication and Weekly
alignment.
Local where the Identify the existence of water or vapors around the gearmotor, excess
gearmotor is of dust, chips or residue; check the gear unit breather, unclogging it if Weekly
installed necessary; check the cooling conditions of the electric motor.
Oil level Check the oil level and complete it if necessary Weekly
Gearmotor mounting
Check if the vibration did not loosen the gearmotor mounting screws. Monthly
screws
Terminais Check if vibration did not loosen the connecting bridges and screws,
Monthly
and screws jeopardizing the contact end the power supply.
Check the conditions of the transmission elements, replacing them if

Mechanical
necessary, and cleaning the gear ratio frame and covers. Biannual
conditions
Check for misalignment of something dragging.
69
70
DEFECTS IN GEAR UNITS
SYMPTOMS CAUSES CORRECTIVE MEASURES
Check the capacity indicated on the gear unit nameplate; replace it by a unit of enough
Overload Load exceeds the gear unit capacity.
capacity or reduce the load.
Overheating
Lock of oil.
Improper Excess of oil the gear unit causes to much agitation, generating heat Check the oil level correct the level.
and gases inside the frame.
lubrication
Drain the oil and refill to the correct level with the oil indicated on the gear unit nameplate
Oil out of specification
or similar product.
Excell of oil. Check the oil level and drain it to the correct level.
Breather for ais ingress end exit of gases clogged Clean or replace the breather; use non flammeble solvent for cleaning.
Lip seal worn out
Oil
Replace the worn outlip seals by new ones. Apply a new sealing layer, permatex or
Ioss
or defective
Insufficient sealing layers between the frame surfaces. equivalent product; assemble the unit. Always install the lip seals with grease on the
sealing lips.
Irregularities on the Check the tightening of the screws and if the anchors are film in the foudation or structure.
Installation inverted.
mounting screws Check alignment os the unit and the spacing plates or shims
Fatigue of the rolling bearings; check for wear on the ball, rollers or tracks; Replace the worn out rolling bearings, clean inside the gear unit and refill with new oil,
Wear may be for dirt in the oil. according to the specification.
Fault on the
Rolling bearing tracks with scales, dents or damaged flanks usually
rolling bearings Replece the worn out rolling bearings; check and repair clearance in the rolling bearings,
indicate overload.
alignment of the coupling and overload on the gear unit shafts.
Excessive Noise
and Vibration Fault on the rolling bearing cages also indicate overload.
Excessive wear Overload causes pitting of the teeth. Check the loads, change the gears or replace by a gear unit of proper load
of the gears
Lack of oil Oil below the regular level may cause noise. Check the oil level and correct it.
Inspect the gear unit. for broken parts, loss of screws, nuts or damaged threads. Check
Loss of parts Excessive shocks or incorrect connection with other elements.
the alignment with the drive machine. Check the keys and tolerances.
Hight speed of Check the speeds indicated on the nameplate. Check the tightening.
Driving pulleys or chains too tight.
the shafts
Excessive Replace the worn out rolling bearings. Clean inside the gear unit. and refill if with the
Clearrance Rolling bearing exposed to abrasive elements cause wear on the balls, rollers and tracks. recommended oil.
on the shafts
Holguras
excesivas en Worn out gears and keys or loss of the screws cause backlash (clearance in the gearing); Replace worn out gears and keys. Tighten all the screws of the unit.
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74
9. ENVIRONMENTAL DIRECTIONS
The products manufactured by WEG-CESTARI meet the legal and environmental requirements defined
by the company, and, as part of our Environmental Management System, the information regarding
the recycling of our products is available in this Manual:
Frame, Couplings, Covers, etc. (Cast Iron, Steel or Aluminium):

They are 100% recyclable and must be sent to foundries.
Shafts, Gears, Pinions, etc. (Steel):

They are 100% recyclable and must be sent to steel plants.
Bevel Gears (Bronze):

They are 100% recyclable and must be sent to foundries.
Oils:
They must be sent for re-refining at duly authorized companies.
Seals (Rubber):
They must be sent to companies duly licensed by the responsible environmental agency (landfill
class II)
Elastic Elements:
They are 100% recyclable and must be sent to recycling companies.
Packages:
Wood: They are made with reforestation wood and may be reused or used as fuel in
boilers when not contaminated (with oil, grease, paint).
Cardboard: They are 100% recyclable when not contaminated (with oil, grease, paint) and
must be sent to recycling companies.
NOTE: If some material is contaminated with oil, grease or paint, it must be sent to
companies duly licensed by the responsible environmental agency.
75
Gear Units Mounting Check List
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Receiveing the gear unit.
Paint Coat
Check for transport dents, paint coat pelling and other imperfections
Oxidation
Check for oxideted spots or areas on the gear unit and acessories
Leaks
Check for lubricant presence on the surface of seals, lids and joints
Machined surfaces protection
Check if machined surfaces are properly covered with protective oil
Components
Check if all components to be used on the mounting process are
present
Breather Seals and Easy-lock components
Check if Breather seal and Easy-Lock components are properly sealed
Storage conditions
Check if gear unit is stored according to Product Manual instructions
Mouting the gear unit

Mouting Position
Check if gear unit is mounted acoording to supplied Mounting position
Lubricant level
Check lubricant level according to Product Manual instructions
Breather seal removal
Check if breather seal was removed BEFORE gear unit start up
Sealing
Check for oil leak presence on any part of the gear unit.
Gear unit mouting recommendations
Check if gear unit mounting on driven machine is in accordance to
Product Manual instructions
76
Easy-Lock system
Check if Easy-Lock system was assembled according to Product Manual
instructions
Machined surfaces oil protection application
Check if protective oil was applied on machined surfaces AFTER gear
unit mounting on drive machine
Brearher Seal Removal
Mounting Positions
Breather must ALWAYS
be on upper side
Verification DATE:
_______/_______/_________
Verification Responsible:
Signature:
77
NOTES
78
ENDEREÇO / DIRECCIÓN / ADDRESS
Rodovia Monte Alto/Vista Alegre | km3

Monte Alto | SP | 15910-000 | Brasil
VENDAS / VENTAS / SALES | +55 (16) 3244-1000 | [email protected]

SERVIÇOS / SERVICIOS / SERVICE | +55 (16) 3244-1020 | [email protected]
SAC / SAC / CUSTOMER SERVICE | +55 (16) 3244-1018 | [email protected]
ASTEC / ASTEC / TEC. ASSIST. | +55 (16) 3244-1010 | [email protected]
www.wegcestari.com

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Guia de Consulta Rápida

Guía de Referencia Rápida

Manual de Instalação, Operação e Manutenção

Redutores, Motorredutores, Partes e Peças

Os dados contidos na Placa de Identificação do redutor são:

 Código: Código do redutor ou motorredutor.

Recomendamos que, quando do recebimento do nosso produto (redutor/motorredutor e/ou partes e

Quando da movimentação de redutores/motorredutores, utilize corda, cabos, cintas e equipamentos

Os redutores/motorredutores deverão ser movimentados utilizando-se do parafuso de suspensão

Figura 2A Figura 2B Figura 2C

Antes de levantar totalmente o redutor/motorredutor, certifique-se de estar a carga devidamente

Os produtos WEG-CESTARI (redutores, motorredutores, partes e peças) devem ser armazenados em

2.1 Período sem funcionamento

Os redutores/motorredutores WEG-CESTARI saem de fábrica e devem ser postos em operação

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Quando o sistema de lubrificação for elétrico, o motor da bomba deve

Consultar a WEG-CESTARI para obtenção da vazão e qualidade de água recomendada; manutenção,

A manutenção preventiva periódica visa principalmente verificar as condições de funcionamento do

Condições Examinar a presença de ruídos ou vibrações anormais,vaza-

Local onde está Identificar a existência de água ou vapores junto ao motorre-

Nível de óleo Verifique o nível de óleo e, se necessário complete-o. Semanal

Terminais Observar se, por vibração não houve o afrouxamento dos

Examinar as condições, dos elementos de transmissão,

SINTOMAS CAUSAS MEDIDAS CORRETIVAS

Barulho excessivo e vibração

Folga Engrenagens e chavetas gastas ou perda dos parafusos causam blacklash

 Carcaças, Acoplamentos, Tampas, etc. (Ferro Fundido, Aço ou Alumínio):

 Eixos, Engrenagens, Pinhões, etc. (Aço):

Madeira: São fabricadas com madeira de reflorestamento e podem ser reutilizadas ou

Remoção do Lacre da Válvula Respiro

Responsável pela Verificação:

Los datos contenidos en la Placa de Identificación del reductor son:

 Código: Código del reductor o motorreductor.

Figura 2A Figura 2B Figura 2C

Antes de levantar totalmente el reductor/motorreductor, asegúrese de que la carga esté debidamente

2.1 Período sin funcionamiento

Los reductores/motorreductores WEG-CESTARI, al salir de fábrica, deberán ser puestos en operación

NOTAS: Antes de la puesta en marcha, el lubricante del reductor/motorreductor deberá ser

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Cuando el sistema de lubricación es eléctrico, el motor de la bomba

Consultar a WEG-CESTARI para obtener el caudal y la calidad del agua recomendada;

Código: Código do redutor ou motorredutor.

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Frame, Couplings, Covers, etc. (Cast Iron, Steel or Aluminium):

Shafts, Gears, Pinions, etc. (Steel):

Bevel Gears (Bronze):